Absorbent core including folded substrate

ABSTRACT

An absorbent core is provided including a substrate that performs at least one fluid handling function. At least a portion of at least one region of the substrate has been modified by aperturing, calendering, coating, creping, heating, printing stretching, or a combination thereof to impart at least one different fluid handling function. The substrate is folded to provide a plurality of panels wherein at least a portion of one panel corresponds to at least a portion of the modified region of the substrate. An absorbent article including the absorbent core and a process for making the absorbent core are also disclosed.

FIELD OF INVENTION

[0001] The present invention relates to an absorbent core that includesa substrate that is folded to provide a plurality of panels at least oneof which performs at least one fluid handling function distinct from atleast one other panel.

BACKGROUND OF THE INVENTION

[0002] Disposable absorbent articles typically include an absorbentassembly constructed from one or more layers of material. Generally,each layer of material is included to provide a distinct fluid handlingfunction within the absorbent article. For example, an absorbentassembly may include a layer of material that promotes rapid intake ofbody exudates such as urine, menses and/or feces, a layer of materialthat promotes distribution of body exudates throughout the absorbentassembly, a layer of material that provides absorbent capacity, and/or alayer of material that serves as a barrier to inhibit and/or preventleakage of body exudates from the absorbent article. Layers of moistureinsensitive adhesives are often included in such absorbent assemblies tohold the individual layers in a desired configuration.

[0003] Unfortunately, these layered assemblies are generally bulky anddo not conform well to the anatomy of the wearer. Additionally, theindividual layers may shift relative to each other due to the wearer'smovement in use resulting in poor fluid management. As a result,absorbent articles including such layered absorbent assemblies may notperform as intended, may have poor fit and may result in discomfortduring use.

[0004] Another potential shortfall of these layered absorbent assemblieslies in the complex and inefficient processes need to produce them.Generally, each layer must be produced separately offline using aspecific technology and then individually fed into the manufacturingprocess. These combined layers are then typically cut to the desiredshape resulting in material waste and cost inefficiencies.

[0005] Personal care product designers have attempted to address variousaspects of these problems in a variety of ways. For example, it is knownto fold an absorbent composite to provide channels or depressions toreceive, distribute and retain body fluids and solid exudates. It isalso known to fold an absorbent composite to provide bulk in the centralor side portions of the absorbent composite to prevent deformation ofthe absorbent composite in use and to assist in distributing ordirecting fluids. Others have utilized designs that reduce waste bycutting an absorbent composite to a particular shape and folding the cutportions into the center or crotch portion of the assembly to provideadditional absorbent capacity. In each case the folding of the absorbentcomposite results in greater bulk in the target area (e.g. the crotch orcentral region and/or side margins). However, for the purposes ofdiscretion and comfort it is desirable to have as thin an absorbentcomposite as possible without sacrificing absorbent capacity.

[0006] Despite all of these techniques there is still a need for anabsorbent core that is thin, durable, structurally stable and performsmultiple functions. There is also a need for an absorbent core whereinthe layers maintain proper position with respect to adjacent layers.Additionally, there is also a need to reduce the bulk of and/oreliminate some of the non-absorbent structural layers to provide apersonal care product having a desired level of fit, comfort andperformance that is more efficient and less expensive to produce.

SUMMARY OF THE INVENTION

[0007] The present invention provides absorbent articles, such asdisposable diapers, training pants, adult incontinence products,sanitary napkins, and the like, that include a folded absorbent corethat provides multiple desired fluid handling functions within a singlecomposite. This capability eliminates the need to include additionalperformance enhancing layers such as surge or wicking layers that addbulk to personal care products.

[0008] The absorbent articles of the present invention include a foldedabsorbent core. Optionally, the folded absorbent core may be positionedintermediate a fluid permeable topsheet and a fluid impermeablebacksheet. The absorbent core includes a substrate that performs atleast one fluid handling function that has been folded to provide aplurality of panels. The substrate may be folded to provide an absorbentcore having one of a variety of suitable cross-sectional configurationsthat may contribute to the overall functionality of the absorbent core.Suitably, the substrate is a single sheet of material that includes atleast one region that has been modified to impart at least one differentfluid handling function. The substrate is folded such that at least onepanel corresponds to at least one region of the substrate that has beenmodified. The substrate may be modified by aperturing, calendaring,coating, creping, heating, printing, stretching or combinations thereof.For example, the substrate may be modified by coating and/or adhering amodifying material such as, but not limited to, an absorbent materiallike superabsorbent material, fibrous material, a binding agent, a fluidand/or menses modifying material, and/or an odor control agent to atleast a portion of the substrate. The binding agent may be an absorbentadhesive, a non-absorbent adhesive, a crosslinking agent or acombination thereof. The absorbent material may be attached directly orindirectly to the substrate by a physical bond or a chemical bond.Desirably, the substrate is folded such that at least a portion of thebinding agent and/or the absorbent material are enclosed within theabsorbent core.

[0009] The folded absorbent core may be used to make personal careproducts such as, for example, diapers, diaper pants, training pants,feminine hygiene products, incontinence products, swimwear garments, bedmats, tissue, wipes, medical articles and the like.

[0010] The absorbent core of the invention may be formed by providing asubstrate, that performs at least one fluid handling function; modifyingat least a portion of one region of the substrate to impart at least onedifferent fluid handling function, and folding the substrate to providea plurality of panels wherein at least a portion of at least one panelcorresponds to at least a portion of the modified region of thesubstrate. The substrate may be modified by aperturing, calendaring,coating, creping, heating, printing, stretching or the like. The processmay further include compressing, densifying, embossing, or shaping thefolded absorbent core to provide a better body fit.

[0011] With the foregoing in mind, it is a feature and advantage of theinvention to provide a thin, durable, structurally stable, andmultifunctional absorbent core. It is a further feature and advantage ofthe invention to provide a personal care product that is thinner, moreefficient and less expensive to manufacture compared to conventionalpersonal care products.

BRIEF DESCRIPTION OF THE DRAWINGS

[0012] These and other objects and features of this invention will bebetter understood from the following detailed description taken inconjunction with the drawings, wherein:

[0013]FIG. 1 illustrates a representative folded absorbent core of thepresent invention.

[0014]FIGS. 2A through 2F are perspective views of representativeabsorbent cores of the present invention having various cross-sectionalprofiles.

[0015]FIGS. 3A through 3C illustrate a method of folding a substrate toprovide an absorbent core including a plurality of panels.

[0016]FIGS. 4A through 4C illustrate representative absorbent cores ofthe present invention including an absorbent in situ neutralizablebinder composition.

[0017]FIGS. 5A and 5B illustrate representative diapers including anabsorbent core of the present invention.

[0018]FIG. 6 is a plan view of a diaper formed from an absorbent core ofthe present invention.

DEFINITIONS

[0019] Within the context of this specification, each term or phrasebelow will include the following meaning or meanings.

[0020] “Attachment mechanism” refers to a mechanism for binding, joiningor securing a first material to a second material.

[0021] “Binder” or “binding agent” refers to a material having binding,adhesive or attachment properties with or without chemical, thermal,pressure or other treatment.

[0022] “Body waste barrier” refers to a fluid handling function whereina substrate assists in preventing the strikethrough of absorbed bodyexudates.

[0023] “Chemical attachment mechanism” or “chemical bonds” refers to amechanism for binding, joining or securing a first material to a secondmaterial that includes, but is not limited to, hydrogen bonding,covalent bonding, crosslinking such as via an in situ polymerizationreaction.

[0024] “Cross-sectional profile” refers to a profile created by a planecutting an absorbent core perpendicular to at least one foldline.

[0025] “Desalination” refers to a fluid handling function wherein anelectrolyte capable of binding sodium ions is brought into contact withan electrolyte capable of binding chloride ions to reduce the localsaline concentration and enhance fluid absorption.

[0026] “Distribution” refers to a fluid handling function wherein afluid is dispersed, wicked, spread, directed or the like within anabsorbent core.

[0027] “Feminine hygiene products” include sanitary pads and napkins, aswell as tampons and interlabial feminine hygiene products.

[0028] “Fluid handling function” refers to an attribute of an absorbentcore that assists in the collection, transport or absorption of fluids.Such fluid handling functions include, but are not limited to, barrierfunction, body contact, desalination, distribution, feces containment,feces modification, intake, lock-up, menses containment, mensesmodification, odor control, retention, and skin treatment.

[0029] “Fluid modifying material” includes, but is not limited to,surfactants that change or modify a physical or chemical property of abody exudates such as urine, feces or menses.

[0030] “Intake” refers to a fluid handling function wherein a materialis capable of capturing a fluid insulted upon an absorbent core.

[0031] “Layer”, as used herein, includes, but is not limited to, singleunfolded sheet or sheets of material, folded sheets of material, stripsof material, loose or bonded fibers, multiple sheets or laminates ofmaterials, or other combinations of such materials.

[0032] “Lock-up” refers to a fluid handling function wherein a fluid isheld within a material and may not be easily given up under pressure.

[0033] “Modifying agent” refers to a substance that may be added to amaterial such as, for example, superabsorbent material, fibers, asubstrate, a binding agent, or a fluid to modify a physical or chemicalproperty of the material. For example, a modifying agent may be added tomodify the viscosity of the fluid or to affect the fluid permeability ofa substrate.

[0034] “Multi-functional” refers to a material that may perform two ormore fluid handling functions.

[0035] “Nonwoven” or “nonwoven web” refers to materials and webs ormaterial having a structure of individual fibers or filaments which areinterlaid, but not in an identifiable manner as in a knitted fabric. Theterms “fiber” and “filament” are used interchangeably. Nonwoven fabricsor webs have been formed from many processes such as, for example,meltblowing processes, spunbonding processes, air laying processes, andbonded carded web processes. The basis weight of nonwoven fabrics isusually expressed in ounces of material per square yard (osy) or gramsper square meter (gsm) and the fiber diameters are usually expressed inmicrons. (Note that to convert from osy to gsm, multiply osy by 33.91.)

[0036] “Panel”, as used herein, includes, but is not limited to, aregion or section of a layer wherein at least a portion of the peripheryof the region or section is defined by a foldline.

[0037] “Personal care product” includes diapers, diaper pants, trainingpants, swim wear, absorbent underpants, adult incontinence products,feminine hygiene products, and the like.

[0038] “Physical attachment mechanism” or “physical bonds” refers to amechanism for binding, joining or securing a first material to a secondmaterial including, but not limited to, heat melting, fiber entanglingand adhesive bonding.

[0039] “Plurality” means two or more elements or parts such as, forexample, an absorbent core including two or more panels.

[0040] “Retention” refers to capacity, storage, containment or similarfluid handling function.

[0041] “Shape” or “shaping” refers to cutting, heating, molding orsimilar process used to impart a desired 2- or 3-dimensionalconfiguration to an absorbent core.

[0042] “Structurally stable” refers to a material capable of maintainingvarious elements, layers or components of an absorbent core in positionwith respect to each other.

[0043] “Substrate” refers to a material having a basis weight of about150 grams per square meter or less, a fluid centrifuge retentioncapacity of about 10 grams fluid per gram material or less and a peaktensile strength under load of at least about 50 grams per centimeterwidth.

[0044] “Superabsorbent” refers to a water-swellable, water-insolubleorganic or inorganic material capable, under the most favorableconditions, of absorbing at least about 10 times its weight and,desirably, at least about 20 times its weight in an aqueous solutioncontaining 0.9 weight percent sodium chloride. The superabsorbentmaterials can be natural, synthetic, and modified natural polymers andmaterials. In addition, the superabsorbent materials can be inorganicmaterials, such as silica gels, or organic compounds such ascross-linked polymers.

[0045] These terms may be defined with additional language in theremaining portions of the specification.

DESCRIPTION OF PREFERRED EMBODIMENTS

[0046] The present invention relates to an absorbent core that includesa substrate that is folded to provide a plurality of panels at least oneof which performs at least one fluid handling function distinct from atleast one other panel. When used in absorbent articles such asdisposable diapers, training pants, adult incontinence products,sanitary napkins, and the like, this capability eliminates the need toinclude additional performance enhancing layers such as surge or wickinglayers that add bulk to and affects the performance, fit and comfort ofpersonal care products.

[0047] Suitably, the absorbent core has an absorbent capacity of about 5grams 0.9 weight percent saline per gram composite or more,alternatively of about 10 grams 0.9 weight percent saline per gramcomposite or more. Desirably, the absorbent core is relatively dense andthus may have a density of at least about 0.5 grams per cubiccentimeter, or at least about 0.7 grams per cubic centimeter.Advantageously, the absorbent core is relatively flexible in order toconform more closely to a wearer's body and inhibit and/or preventleakage when included in a personal care product. Therefore, theabsorbent core may have a Gurley stiffness value of about 320 milligramsor less, especially about 160 milligrams or less. Preferably, theabsorbent core is also relatively thin in order to provide better fitand comfort when included in a personal care product. Therefore, theabsorbent core may have a thickness of about 0.2 to about 4 millimeters.

[0048] Referring to FIG. 1, an absorbent core 10 includes a substrate 12that is folded upon itself to form an absorbent core having a pluralityof panels 14. For example, as shown in FIG. 1A, the absorbent coreincludes three panels, 14, 14′ and 14″ respectively.

[0049] Desirably, the substrate 12 is a single sheet or layer ofmaterial that performs at least one fluid handling function (e.g. a basefluid handling function) and may be modified to provide two or moredesired fluid handling functions such as, but not limited to, barrierfunction, body contact, distribution, feces containment, fecesmodification, intake, lock-up, menses containment, menses modification,odor control, retention, and skin treatment.

[0050] The substrate 12 may have a basis weight of about 150 grams persquare meter or less and a fluid centrifuge retention capacity of about10 grams 0.9 weight percent saline per gram substrate or less.Advantageously, the substrate 12 may be a sheet having a peak tensilestrength under load of at least about 50 grams per centimeter width.Suitable substrates 12 include, but are not limited to, nonwoven, woven,and knitted fabrics; cellulosic tissue sheets; plastic films, includingpolypropylene, low density polyethylene, high density polyethylene,linear low density polyethylene, and ultra low density polyethylene;styrene-ethylene-butylene-styrene or styrene-isoprene-styrene blockcopolymers, KRATON polymers from Kraton Polymers of Houston, Tex.,metallocene catalyzed elastomers or plastomers, and the like orcombinations thereof. Other suitable substrates include monolithicbreathable films, such as those made of polyether amide based polymers,for example PEBAX available from Atofina Chemical Company ofPhiladelphia, Pa., and ether/ester polyurethane thermal-plasticelastomers; LYCRA stranded composites; and elastomer net composites.

[0051] The substrate 12 may be folded in any manner in order to providean absorbent core 10 having at least two panels. Specifically, thesubstrate 12 may be folded to provide a particular cross-sectionalprofile. For example, the substrate 12 may be folded to provide at leastthree panels. In particular, as illustrated in FIG. 2A, the absorbentcore 10 has an “e”-shape cross sectional profile 16 including threepanels, 14, 14′ and 14″ respectively. FIG. 2B illustrates an absorbentcore 10 having a “z”-shape cross-section 18 including three panels, 14,14′ and 14″ respectively. Additionally, FIG. 2C depicts an absorbentcore 10 including three panels, 14, 14′ and 14″ respectively, having a“c”-shape cross-section 20.

[0052] Other suitable cross-sectional profiles are illustrated in FIGS.2D through 2F. For example, FIG. 2D depicts an absorbent core 10 havinga “sigma”-shaped cross-section 22 including four panels. FIG. 2E showsan absorbent core 10 having a “u”-shaped cross-section 24 including twopanels while FIG. 2F shows an absorbent core 10 having an“accordion”-shaped cross-section 26 including seven panels.Additionally, the substrate 12 may be folded in any other manner suchthat the resulting absorbent core 10 includes at least two panels.Suitably, the substrate may be cut, slit, scored, perforated, aperturedor the like to facilitate folding.

[0053] In a representative folding operation, as shown in FIGS. 3Athrough 3C, the substrate 12 may be folded to form an absorbent core 10including three panels and having an “e”-shaped cross-section. Referringto FIG. 3A, a substrate 12 including a first region 28, a central region30 and a second region 32 is folded along a first foldline 34 such thata first edge 36 of the substrate is positioned adjacent a secondfoldline 38 and the first region 28 overlays the central region 30 asshown in FIG. 3B. As shown in FIG. 3C, the substrate 12 is then foldedalong the second foldline 38 such that a second edge 40 of the substrate12 is positioned adjacent the first foldline 34 and the second region 32overlays the first region 28 to provide an absorbent core 10 having an“e”-shaped cross-section. Alternatively, the substrate 12 could befolded in the reverse order such that the second region 32 overlays thecentral region 30 and the first region 28 overlays the second region 32to provide an absorbent core 10 having an “e”-shaped cross-section.

[0054] At least a portion of at least one region of the substrate ismodified to provide at least one fluid handling function that isdifferent from the base function of the substrate. Suitably, thesubstrate is folded such that at least one panel of the absorbent corecorresponds to at least one modified region of the substrate. Forexample, a first panel of the absorbent may perform a first fluidhandling function as provided by the substrate (e.g. the base fluidhandling function) and at least a portion of at least a second panel ofthe folded substrate may correspond to a region of the substrate thathas been modified to perform a different fluid handling function therebyproviding a folded absorbent core that performs at least two fluidhandling functions. Furthermore, an individual panel may perform morethan one fluid handling function. Suitably, each panel of the absorbentcore may perform at least one different fluid handling function in orderto maximize the utility of the absorbent core.

[0055] The desired fluid handling function or functions may be impartedto an individual panel of the absorbent core through a variety ofmethods. A fluid handling function may be imparted to the substrate bymethods including, but not limited to, aperturing, calendering, coating,creping, heating, printing, or stretching at least a portion of thesubstrate.

[0056] In one embodiment, at least a portion of the substrate 12 iscoated or treated with a modifying material to impart a desired fluidhandling function different than the base function of the substrate andthe substrate is folded to provide an absorbent core having at least onepanel that corresponds to the modified region of the substrate. Examplesof modifying materials include, but are not limited to fluid modifyingmaterials, binding agents, absorbent materials, and odor control agents.More than one modifying material may be coated or applied on the sameregion or portion of the substrate.

[0057] For example, at least a portion of a substrate may be coated ortreated with a fluid modifying material such as, for example, aviscoelastant or a surfactant. A “viscoelastant” is an organic agentthat, when an effective amount is contacted by a viscoelasticcomposition, materially alters the properties of that viscoelasticcomposition, for example, by reducing its viscosity and/or elasticnature. A viscoelastant may be applied to at least a portion of thesubstrate 12 as a menses modifying material and/or a feces-modifyingmaterial.

[0058] A suitable viscoelastant for use in the present inventionincludes an alkyl polyglycoside including 8-10 carbon atoms in the alkylchain. Alkyl polyglycosides alter the viscoelastic properties ofviscoelastic fluids such as menses and feces as well as increase thewettability of synthetic surfaces. One specific viscoelastant suitablefor use in the present invention is an alkyl polyglycoside availableunder the trademark GLUCOPON 220UP from Cognis Corporation of Ambler,Pa.

[0059] Other examples of suitable viscoelastants include bovine lipidextract surfactant, available under the registered trademark SURVANTAfrom Ross Laboratories of Columbus, Ohio, a drug used to treat AcuteRespiratory Distress Syndrome and Cystic Fibrosis, and enzymes such aspapain and pepsin which cleave protein structures. Some dextrins anddextrans may also be used as viscoelastants. Dextrans (macrose) arepolymers of glucose with chain-like structures and molecular weight of,for example, about 200,000 or less produced from sucrose, often bybacterial action. Dextrins (starch gum) are normally solid starchderivatives formed when starch is heated either alone or with nitricacid. A suitable dextran for use in the present invention includes a4000 MW oligosaccharide available from Polydex Pharmaceuticals, Ltd. ofScarborough, Ontario, Canada.

[0060] The addition of the viscoelastant to the substrate may beaccomplished by conventional means such as spraying, coating, dippingand the like. Alternatively, in some cases it may be advantageous to addthe viscoelastant as an internal additive to the polymer melt used toform the substrate. The amount of viscoelastant applied will depend uponthe particular end use as well as factors such as basis weight andporosity of the substrate. Other examples of viscoelastants and methodsof application are disclosed in commonly assigned U.S. Pat. No.6,060,636 to Yahiaoui et al., which is incorporated by reference.

[0061] Surfactants may be applied to one or more regions of thesubstrate 12 in order to improve the fluid permeability or wettabilityof the substrate, particularly those including substantially hydrophobicmaterials such as polypropylene, polyethylene, and the like. Suitablesurfactants may include amphoteric, anionic, cationic, nonionic, andzwitterionic surfactants. For example, the substrate 12 may be treatedwith about 0.45 weight percent of a surfactant mixture including AHCOVELN-62 available from Uniqema Inc., a division of ICI of New Castle, Del.,U.S.A. and GLUCOPON 220UP available from Cognis Corporation of Ambler,Pa., and produced in Cincinnati, Ohio, in an active ratio of 3:1. Thesurfactant can be applied by any conventional means, such as spraying,printing, brush coating or the like. The surfactant can be applied tothe entire substrate 12 or can be selectively applied to particularregions or surfaces of the substrate 12, such as a medial region along alongitudinal centerline or either a top surface or an opposing bottomsurface.

[0062] In one aspect, at least one region of the substrate may be coatedwith a binding agent such that when the substrate is folded at least aportion of at least one panel is coated with the binding agent. Thebinding agent may include an absorbent adhesive composition, anon-absorbent adhesive composition, or a combination thereof. Theabsorbent adhesive composition may be an in situ neutralizable bindercomposition, an in situ polymerizable binder composition, acrosslinkable binder composition, or a combination thereof. Absorbentadhesive compositions may be coated onto at least a portion of asubstantially non-absorbent substrate such as for example, an aperturedfilm, to provide an absorbent core having intake, barrier and fluidretention functionality. The binding agent may be used alone or incombination with an absorbent material such as superabsorbent, a fluidmodifying agent, and/or an odor control agent.

[0063] One suitable absorbent adhesive composition may include anabsorbent in situ neutralizable binder composition. The absorbent insitu neutralizable binder composition may include a copolymer of anunneutralized polyacid and a polyamine binder material. Theunneutralized polyacid may be selected from poly(acrylic acid),poly(methacrylic acid), poly(maleic acid), carboxymethyl cellulose,alginic acid, poly(aspartic acid), and poly(glutamic acid). Suitably,the polyacid includes poly(acrylic acid). The polyamine binder materialmay be selected from poly(vinylamine), a polyethylenimine, apoly(vinylguanidine), a poly(allylamine), a poly(allylguanidine), apoly(lysine), a poly(arginine), a poly(histidine), apoly(dialkylaminoalkyl (meth)acrylamide) and copolymers containinglysine, arginine, and histidine. Suitably, the polyamine binder materialincludes poly(vinylamine).

[0064] Desirably, the copolymer of an unneutralized polyacid and thepolyamine binder material are coated onto the substrate 12 as one ormore separate layers. For example, referring to FIGS. 4A through 4C, oneor more layers of a copolymer of an unneutralized polyacid 42 are coatedonto the substrate 12 and one or more layers of the polyamine bindermaterial 44 are coated onto the same or different portions of thesubstrate such that when the substrate 12 is folded layer or layers 42and 44 are brought together. Without wishing to be bound by theory, itis believed that providing a copolymer of an unneutralized polyacidtogether with a polyamine binder material forms a macro bipolarabsorbent film that is capable of desalinating an electrolyte-containingfluid. Desalinating the electrolyte-containing solution is believed toaid in fluid absorption and retention within the absorbent core 10,especially when the absorbent adhesive composition includes asuperabsorbent material, by inhibiting or preventing a salt poisoningeffect which may reduce the capacity of the absorbent adhesivecomposition and/or the superabsorbent material. The layers 42 and 44 maybe applied to the substrate 12 in any configuration that brings layer 42together with layer 44. For example, the layer 42 may be brought intodirect contact with layer 44. Alternatively, a third layer, such as anonionic, liquid permeable membrane or an open structure such as ascreen can be used as a mediator to allow the reaction between layer 42and layer 44 to occur.

[0065] Another suitable absorbent adhesive composition includes an insitu polymerizable binder composition. One suitable in situpolymerizable binder composition is disclosed in U.S. Pat. No. 6,417,425to Whitmore et al. which is hereby incorporated by reference. The insitu polymerizable binder composition may be prepared as a sprayableaqueous solution containing a superabsorbent forming monomer and aninitiator. Suitable superabsorbent forming monomers includemonoethylenically unsaturated compounds (or compounds having apolymerizable double bond) having at least one hydrophilic radical suchas carboxyl, carboxylic acid salt, sulfonic acid, sulfonic acid salt,hydroxyl, ether, amide, amino or quaternary ammonium salt groups.Suitable initiators include redox initiators and thermal initiators.Examples of suitable initiators systems may found in U.S. Pat. No.4,497,903 to Yamasaki et al. and U.S. Pat. No. 5,145,906 to Chamber etal., the disclosures of which are hereby incorporated by reference. Thein situ polymerizable binder composition may be applied to a substrateand thereafter is subjected to conditions under which the superabsorbentforming monomers will polymerize. Such condition may include, forexample, subjecting the in situ polymerizable binder composition toheat, ultraviolet radiation, e-beam radiation, or a combination thereof.After the superabsorbent forming monomers have been polymerized thecoated substrate may be dried to remove any remaining water.

[0066] An additional absorbent adhesive composition suitable for use inthe present invention includes an absorbent crosslinkable bindercomposition. The absorbent crosslinkable binder composition may includesoluble polymers such as hydrophilic polymers, or blends of hydrophilicpolymers or hydrophobic polymers containing hydrophilic agents.Suitably, the crosslinkable binder composition may include a latentcrosslinker composed of multivalent metal ions. An example of a suitablebinder includes an alkoxysilane grafted poly(ethylene oxide) (“gPEO”)that is soluble in alcohol solvents that do not substantially swell ordissolve superabsorbent material. As used herein, the term“substantially swell” refers to a substance that causes a particle toswell, thereby increasing in volume by at least 10 percent. Morespecifically, the gPEO, upon exposure to moisture, crosslinks into a gelstructure capable of absorbing relatively large amounts of fluids, suchas water or saline. This type of binder is capable of crosslinkingduring the solvent drying or evaporating process to provide enhanced wetattachment. Methacryloxypropyl trimethoxy silane is one example of asuitable alkoxysilane grafting monomer.

[0067] Water-soluble polymers useful in the present invention include,but are not limited to, poly(alkylene oxides), such as poly(ethyleneoxide) (“PEO”), poly(ethylene glycols), block copolymers of ethyleneoxide and propylene oxide, poly(vinyl alcohol) and poly(alkyl vinylethers). These water-soluble polymers must be capable of graftpolymerization with an organic moiety containing a trialkoxy silanefunctional group or a moiety that reacts with water to form a silanolgroup. The preferred water-soluble polymer for use in the presentinvention is PEO.

[0068] Other suitable binders include monoethylenically unsaturatedcarboxylic, sulphonic or phosphoric acids, or salts thereof, and anacrylate or methacrylate ester that contains an alkoxysilanefunctionality which, upon exposure to water, forms a silanol functionalgroup which condenses to form a crosslinked polymer.

[0069] The binders used in the invention should provide very flexiblecoatings and should therefore have a glass transition temperature ofabout 30 degrees Celsius or lower, or about 10 degrees Celsius or lower,as measured by a Differential Scanning Calorimeter (DSC). Thecrosslinkable binder composition desirably has a bending modulus lowerthan the bending modulus of the substrate.

[0070] Organic monomers capable of graft polymerization with PEO orco-polymerization with monoethylenically unsaturated carboxylic,sulphonic or phosphoric acid or salts thereof, which monomers contain atrialkoxy silane functional group or a moiety that reacts with water toform a silanol group, are useful in the practice of this invention. Theterm “monomer(s)” as used herein includes monomers, oligomers, polymers,mixtures of monomers, oligomers and/or polymers, and any other reactivechemical species which is capable of co-polymerization withmonoethylenically unsaturated carboxylic, sulphonic or phosphoric acidor salts thereof. Ethylenically unsaturated monomers containing atrialkoxy silane functional group are appropriate for this invention andare desired. Desired ethylenically unsaturated monomers includeacrylates and methacrylates. A particularly desirable ethylenicallyunsaturated monomer containing a trialkoxy silane functional group ismethacryloxypropyl trimethoxy silane, commercially available from DowComing, having offices in Midland, Mich., under the trade designationZ-6030 Silane. Other suitable ethylenically unsaturated monomerscontaining a trialkoxy silane functional group include, but are notlimited to, methacryloxyethyl trimethoxy silane, methacryloxypropyltriethoxy silane, methacryloxypropyl tripropoxy silane,acryloxypropylmethyl dimethoxy silane, 3-acryloxypropyl trimethoxysilane, 3-methacryloxypropylmethyl diethoxy silane,3-methacryloxypropylmethyl dimethoxy silane, and 3-methacryloxypropyltris(methoxyethoxy) silane. However, it is contemplated that a widerange of vinyl and acrylic monomers having trialkoxy silane functionalgroups or a moiety that reacts easily with water to form a silanolgroup, such as a chlorosilane or an acetoxysilane, are effectivemonomers for copolymerization in accordance with the present invention.

[0071] The amount of organic monomer having trialkoxy silane functionalgroups or silanol-forming functional groups relative to the amount ofPEO may range from about 0.1 to about 20 weight percent of monomer tothe weight of PEO. Desirably, the amount of monomer should exceed 0.1weight percent in order to sufficiently improve the processability ofthe PEO. Typically, the monomer addition levels are between about 1.0percent and about 15 percent of the weight of the base PEO resin;particularly, between about 1.0 percent and about 10 percent of theweight of the base PEO resin; especially, between about 1.5 percent andabout 5.5 percent of the weight of the base PEO resin for some intendeduses. Suitably, the grafting level may be in the range of 0.5 to about10 weight percent relative to the weight of the PEO.

[0072] The amount of organic monomer having trialkoxy silane functionalgroups or silanol-forming functional groups relative to the weight of acrosslinkable binder composition including a monoethylenicallyunsaturated carboxylic, sulphonic or phosphoric acid or salts thereofmay range from about 0.1 to about 15 weight percent. Desirably, theamount of monomer should exceed 0.1 weight percent in order to providesufficient crosslinking upon exposure to moisture. Typically, themonomer addition levels are between about 1.0 percent and about 15percent of the weight of the polymeric binder composition; particularly,between about 1.0 percent and about 10 percent of the weight of thepolymeric binder composition; especially, between about 1.5 percent andabout 5.5 percent of the weight of the polymeric binder composition forsome intended uses.

[0073] Optionally, the polymeric binder may include long chain,hydrophilic monoethylenically unsaturated esters, such as poly(ethyleneglycol) methacrylate having from 1 to 13 ethylene glycol units,particularly, between 2 and 10 ethylene glycol units; especially,between 3 and 6 ethylene glycol units.

[0074] Suitable acrylic acid salts for use in combination withpoly(ethylene glycol) methacrylate include sodium acrylate, potassiumacrylate, ammonium acrylate, and quaternary amine acrylate.

[0075] The amount of monoethylenically unsaturated hydrophilic estersrelative to the weight of the polymeric binder composition thereof mayrange from about 0 to about 75 weight percent of monomer to the weightof the polymeric binder composition. Typically, the monomer additionlevels are between about 10 percent and about 60 percent of the weightof the polymeric binder composition; particularly, between about 20percent and about 50 percent of the weight of the polymeric bindercomposition; especially, between about 30 percent and about 40 percentof the weight of the polymeric binder composition for some intendeduses.

[0076] Crosslinking of the binder is induced after the crosslinkablebinder composition has been applied to the substrate. Crosslinking maybe induced by a variety of techniques including thermal initiation,radiation initiation, redox chemical reactions, multivalent metal ions,and moisture. Various types of effective radiation initiation includeultraviolet, microwave, and electron-beam radiation. Moisture initiationmay be accomplished through hydrolysis and condensation. Multivalentmetal ions can initiate crosslinking by complexation. After inducingcrosslinking of the binder, the solvent (if present) can be removed fromthe substrate, either by drying the substrate or using any othereffective technique to evaporate the solvent.

[0077] Alternatively, one or more regions of the substrate 12 may becoated with a non-absorbent adhesive composition. The non-absorbentadhesive composition may be used to form a fluid barrier on one or moresurfaces of the substrate, may be used to bind another material such asan absorbent material to the substrate, or may be used to secure thesubstrate in a folded configuration. Suitable non-absorbent adhesivecompositions, which can be applied continuously or intermittently asbeads, a spray, parallel swirls, or the like, can be obtained fromFindley Adhesives, Inc., of Wauwatosa, Wis., or from National Starch andChemical Company, Bridgewater, N.J. Another suitable non-absorbentadhesive composition includes a latex based adhesive.

[0078] In another aspect, at least a portion of the substrate 12 may betreated or coated with or may contain an absorbent material. Suitably,the absorbent material has an absorbent capacity of about 7 grams 0.9weight percent saline per gram absorbent material or more. One suchabsorbent material includes superabsorbent material.

[0079] The superabsorbent material may be of any suitable chemistry toprovide absorbency under anticipated usage conditions. Suitablechemistries include crosslinked forms of sodium polyacrylate, sodiumpolymethacrylate, polyacrylamide, carboxymethyl cellulose, graftedstarch, poly(sodium aspartate), poly(vinyl amine), poly(dimethyldiallylamine), chitosan salt, and/or poly(ethylene imine). Superabsorbentmaterials are available from various commercial vendors, such as DowChemical Company located in Midland, Mich., and Stockhausen GmbH & Co.KG, D-47805 Krefeld, Federal Republic of Germany. Typically, asuperabsorbent material is capable of absorbing at least about 15 timesits weight in water, and desirably is capable of absorbing more thanabout 25 times its weight in water. The superabsorbent material may bepresent in the absorbent core 10 in an amount of about 95 weight percentor less based on the weight of the absorbent core.

[0080] Particle size and geometry of the superabsorbent material may bewhatever is suitable for a particular means of applying thesuperabsorbent material to the substrate 12. For example, thesuperabsorbent material may be spherical, platelet-like, fibrous, or anyrelated geometry. In the unswollen state, the superabsorbent materialmay have cross-sectional diameters in a range from about 50 to about 800microns, or from about 200 to about 400 microns, and for some printingapplications from about 60 to about 80 microns, as determined by sieveanalysis according to the American Society for Testing Materials (ASTM)Test Method D-1921. Alternatively, the superabsorbent material may beformed on the substrate via an in situ polymerization reaction. It isunderstood that the particles of material falling within these rangesmay include solid particles, porous particles, or may be agglomeratedparticles including many smaller particles agglomerated into particleswithin the described size ranges.

[0081] Suitably, an attachment mechanism for securing the absorbentmaterial to at least one region of the substrate is provided. Suchattachment mechanism includes, but is not limited to, physical bonds,chemical bonds and combinations thereof.

[0082] Desirably, the substrate 12 is folded such that at least aportion of modifying material, e.g. the fluid-modifying material, thebinding agent or the absorbent material, is enclosed within theabsorbent core 10. This is desirable to prevent leakage or seepage offluid or the modifying material from the absorbent core 10.

[0083] The modifying material may be applied to the substrate using anysuitable application process, including knife over roll coating, or rollcoating, either in a continuous coverage or a patterned coverage.Printing applications are other suitable application techniques,including gravure printing, screen, and jet printing.

[0084] In another embodiment, at least a portion of at least one regionof substrate 12 is physically modified to impart a desired fluidhandling function different to the base function of the substrate andthe substrate is folded to provide an absorbent core having at least onepanel that corresponds to the modified region of the substrate. Examplesof physical modifications of the substrate include, but are not limitedto, aperturing, calendering, creping, heating or stretching at least aportion of the substrate.

[0085] For example, a portion or region of a substrate such as acellulosic tissue web can be modified by forming a plurality ofapertures. The cellulosic tissue web may then be folded to provide aplurality of panels wherein at least a portion of one panel correspondsto the apertured region. Suitably, the substrate is folded in such amanner that the apertured panel forms at least a portion of one of anopposing top or bottom surface of the absorbent core in order to providefluid access to the apertures. The resulting absorbent core wouldperform at least two fluid handling functions: distribution (the basefunction provided by the substrate); and intake provided by theapertured panel of the absorbent core.

[0086] Similarly, at least a portion or region of a film such asthermoplastic film including polyethylene, polypropylene or the like maybe modified to provide a plurality of apertures and may thereafter befolded to provide an absorbent core having a plurality of panels whereinat least one panel corresponds to the apertured region of the filmsubstrate. Suitably, the substrate is folded in such a manner that theapertured panel forms at least a portion of one of an opposing top orbottom surface of the absorbent core in order to provide fluid access tothe apertures. The resulting absorbent core would perform at least twofluid handling functions: barrier function (the base function of thesubstrate) and intake provided by the apertured panel of the absorbentcore.

[0087] In another aspect, at least a portion of a substrate such asnonwoven material may be calendered to provide at least one regionhaving a different density than the uncalendered portion or portions ofthe substrate. The substrate may thereafter be folded to provide anabsorbent core having a plurality of panels wherein at least one panelcorresponds to at least a portion of the modified region of thesubstrate. The resulting absorbent core would perform at least two fluidhandling functions: intake (the base function of the substrate) anddistribution provided by the calendered or densified panel of theabsorbent core.

[0088] In any of the preceding embodiments, the substrate may bemodified by both coating a region of the substrate with a modifyingagent and physically modifying the same or a different region of thesubstrate region. The resulting modified substrate may be folded in anymanner appropriate to provide an absorbent core having a plurality ofpanels wherein at least one panel corresponds to at least one modifiedregion of the substrate.

[0089] A process for making an absorbent core 10 of the presentinvention includes: providing a substrate that performs at least a firsthandling function; modifying the substrate by aperturing, calendering,coating, creping, heating, printing, stretching or a combination thereofat least one region of the substrate to impart at least one differentfluid handling function; and folding the substrate to provide aplurality of panels such that at least a portion of at least one panelcorresponds to the modified region of the substrate.

[0090] The process for making the absorbent composite 10 may optionallyinclude the steps of cutting, embossing, bonding, pressing and/orshaping the folded substrate to impart additional fluid handlingfunctionality and/or aesthetic properties to the absorbent composite 10.For example, the folded substrate 12 may be embossed with one of anumber of discreet bond patterns. One example of a pattern is the Hansenand Pennings or “H&P” pattern as taught in U.S. Pat. No. 3,855,046 toHansen and Pennings. Another typical embossing pattern is the expandedHansen and Pennings or “EHP”. Other common patterns include a “Ramisch”diamond pattern with repeating diamonds and an “S” weave pattern asdescribed in commonly assigned U.S. Pat. No. 5,964,742 to McCormack etal., which is incorporated by reference. Additional patterns include,for example, cross directional lines, machine directional lines or otherextensible patterns known in the art. One such extensible patternsuitable for use in the present invention is known as “wire weave”.

[0091] The absorbent core 10 of the invention can be incorporated intoany suitable absorbent article. Furthermore, the absorbent core 10 maybe positioned or oriented within the absorbent article in any mannerthat provides the desired fluid handling properties. The absorbent core10 of the invention is particularly suitable for absorbing liquids suchas urine, menses, feces, or sweat, or gases, especially malodorousgases. Examples of absorbent articles that may include an absorbent core10 include absorbent garments such as training pants, diapers, diaperpants, feminine hygiene products, swimwear, incontinence products, otherpersonal care or health care garments, including medical garments, orthe like and absorbent products such as wipes, tissues, underarm sweatpads and bed mats or pads. As used herein, the term “incontinenceproducts” includes absorbent underwear for children, absorbent garmentsfor children or young adults with special needs such as autisticchildren or others with bladder/bowel control problems as a result ofphysical disabilities, as well as absorbent garments for incontinentolder adults. As used herein the term “feminine hygiene product”includes sanitary pads and napkins, as well as tampons and interlabialfeminine hygiene products.

[0092] Desirably, absorbent articles including an absorbent core 10 ofthe present invention should have an average thickness of about 6.4millimeters or less. Furthermore, the structural components of anabsorbent article including an absorbent core 10 of the presentinvention suitably have a thickness of between about 0.2 and about 4millimeters (mm), or between about 0.5 and about 3.0 mm, or betweenabout 1.0 and about 2.5 mm, as measured at 0.05 pounds square inch (psi)(0.34 kPascals), and an absorbent capacity of between about 0.1 andabout 1.8 g/cm², or between about 0.5 and about 1.4 g/cm², or betweenabout 0.7 and about 1.1 g/cm² under an applied load of 0.3 psi (2.07kPascals). The absorbent capacity of the material can be measuredaccording to the test method described in detail below.

[0093] In one aspect, the absorbent core 10 can be incorporated into anabsorbent garment. For ease of explanation, the description hereafterwill be in terms of the absorbent core 10 incorporated into a diaper 46.As shown in FIG. 5A, a diaper 46 having refastenable sides in a fastenedposition defines a three-dimensional configuration having a waistopening 48 and a pair of leg openings 50. Referring to FIGS. 5A and 5B,the diaper 46 includes a body-side liner 52 which is configured tocontact the wearer, and an outer cover 54 opposite the body-side linerwhich is configured to contact the wearer's clothing. An absorbentassembly 56 is positioned or disposed between the outer cover 54 and thebody-side liner 52. In one embodiment an absorbent core 10 of theinvention may be inserted into the diaper as the absorbent assembly 56.

[0094] The outer cover 54 desirably includes a material that issubstantially liquid impermeable, and can be elastic, stretchable ornonstretchable. The outer cover 54 can be a single layer of liquidimpermeable material, but desirably includes a multi-layered laminatestructure in which at least one of the layers is liquid impermeable. Forinstance, the outer cover 54 can include a liquid permeable outer layerand a liquid impermeable inner layer that are suitably joined togetherby a laminate adhesive (not shown). Suitable laminate adhesives, whichcan be applied continuously or intermittently as beads, a spray,parallel swirls, or the like, can be obtained from Findley Adhesives,Inc., of Wauwatosa, Wis., or from National Starch and Chemical Company,Bridgewater, N.J. The liquid permeable outer layer can be any suitablematerial and desirably one that provides a generally cloth-like texture.One example of such a material is a 20-grams per square meter (gsm)spunbond polypropylene nonwoven web. The outer layer may also be made ofthose materials of which liquid permeable body-side liner 52 is made.While it is not a necessity for the outer layer to be liquid permeable,it is desired that it provides a relatively cloth-like texture to thewearer.

[0095] The inner layer of the outer cover 54 can be both liquid andvapor impermeable, or can be liquid impermeable and vapor permeable. Theinner layer is desirably manufactured from a thin plastic film, althoughother flexible liquid impermeable materials may also be used. The innerlayer, or the liquid impermeable outer cover 54 when a single layer,prevents waste material from wetting articles, such as bedsheets andclothing, as well as the wearer and care giver. A suitable liquidimpermeable film for use as a liquid impermeable inner layer, or asingle layer liquid impermeable outer cover 54, is a 0.2 millimeterpolyethylene film commercially available from Huntsman Packaging ofNewport News, Va. If the outer cover 54 is a single layer of material,it can be embossed and/or matte finished to provide a more cloth-likeappearance. As earlier mentioned, the liquid impermeable material canpermit vapors to escape from the interior of the disposable absorbentarticle, while still preventing liquids from passing through the outercover 54. A suitable breathable material is composed of a microporouspolymer film or a nonwoven fabric that has been coated or otherwisetreated to impart a desired level of liquid impermeability. A suitablemicroporous film is a PMP-1 film material commercially available fromMitsui Toatsu Chemicals, Inc., Tokyo, Japan, or an XKO-8044 polyolefinfilm commercially available from 3M Company, Minneapolis, Minn.

[0096] Certain non-breathable elastic films can also be used to make theouter cover 68. Examples of suitable non-breathable films can be made ofstyrene-ethylene-butylene-styrene or styrene-isoprene-styrene blockcopolymers, KRATON polymers from Kraton Polymers of Houston, Tex.,metallocene catalyzed elastomers or plastomers, and the like. Othermaterials suitable for making the outer cover 54 include monolithicbreathable films, such as those made of polyether amide based polymers,for example PEBAX from Atofina Chemicals, Inc. of Philadelphia, Pa., andether/ester polyurethane thermal-plastic elastomers.

[0097] The liquid permeable body-side liner 52 is illustrated asoverlying the outer cover 54 and absorbent assembly 56, and may but neednot have the same dimensions as the outer cover 54. The body-side liner52 is desirably compliant, soft feeling, and non-irritating to thewearer's skin. Further, the body-side liner 52 can be less hydrophilicthan the absorbent assembly 56, to present a relatively dry surface tothe wearer and permit liquid to readily penetrate through its thickness.

[0098] The body-side liner 52 can be manufactured from a wide selectionof web materials, such as synthetic fibers (for example, polyester orpolypropylene fibers), natural fibers (for example, wood or cottonfibers), a combination of natural and synthetic fibers, porous foams,reticulated foams, apertured plastic films, or the like. Various wovenand nonwoven fabrics can be used for the body-side liner 52. Forexample, the body-side liner can be composed of a meltblown orspunbonded web of polyolefin fibers. The body-side liner can also be abonded-carded web composed of natural and/or synthetic fibers. Thebody-side liner can be composed of a substantially hydrophobic material,and the hydrophobic material can, optionally, be treated with asurfactant or otherwise processed to impart a desired level ofwettability and hydrophilicity. For example, the material can be surfacetreated with about 0.45 weight percent of a surfactant mixture includingAHCOVEL N-62 available from Uniqema Inc., a division of ICI of NewCastle, Del. and GLUCOPON 220UP available from Cognis Corporation ofAmbler, Pa., and produced in Cincinnati, Ohio, in an active ratio of3:1. The surfactant can be applied by any conventional means, such asspraying, printing, brush coating or the like. The surfactant can beapplied to the entire body-side liner 52 or can be selectively appliedto particular sections of the body-side liner, such as the medialsection along the longitudinal centerline.

[0099] Non-absorbent structural components in the diaper 46 may includea pair of transversely opposed front side panels 58, and a pair oftransversely opposed back side panels 60. The side panels 58, 60 may beintegrally formed with the outer cover 54 and/or the body-side liner 52,or may include two or more separate elements.

[0100] Other non-absorbent structural components in the diaper 46 mayinclude a pair of containment flaps 62 which are configured to provide abarrier to the transverse flow of any body exudates discharged from thewearer. A flap elastic member 64 may be operatively joined with eachcontainment flap 62 in any suitable manner as is well known in the art.The elasticized containment flaps 62 define an unattached edge thatassumes an upright, generally perpendicular configuration in at least acrotch region of the diaper 46 to form a seal against the wearer's body.The containment flaps 62 can be located along transversely opposed sideedges of the diaper 46, and can extend longitudinally along the entirelength of the training pant or may only extend partially along thelength of the diaper. Suitable constructions and arrangements for thecontainment flaps 62 are generally well known to those skilled in theart.

[0101] In another aspect, an absorbent core 10 of the present inventionmay be used to form an absorbent garment. For example, an absorbentgarment may include an absorbent core including a substrate, at least aportion of which is coated with an absorbent adhesive composition, whichis folded to provide a plurality of panels at least one of which formsan outer cover of the garment.

[0102] In a specific embodiment, the absorbent core 10 may be used toform a diaper 46. Referring to FIG. 6, a diaper 46 includes an absorbentcore 10 and a pair of fastening means 66. The absorbent core 10 includesa substrate 12 having a pair of longitudinal ends 68 and a pair oftransverse edges 70. The substrate 12 includes a sheet of a nonwovenmaterial 72, having a width dimension and a length dimension, such as,for example, a 20-gram per square meter (gsm) spunbond polypropylenenonwoven web, at least a portion of which is laminated to a sheet ofbreathable film 74 such as, for example, a microporous polymer film.Suitably, the breathable film 74 has a length dimension comparable tothe length dimension of the nonwoven material and a width dimension thatis smaller than the width dimension of the nonwoven material.Advantageously, the breathable film 74 is laminated to the nonwovensheet 72 in a medial section 76 of the substrate 12. The breathable film74 may be laminated to the nonwoven sheet 72 by any means known in theart such as, for example, heat embossing, thermal bonding, ultrasonicwelding, and/or adhesive lamination.

[0103] Desirably, an absorbent adhesive composition is applied to atleast a portion of the substrate 12, alternatively to at least a portionof the substrate 12 where the nonwoven sheet 72 is laminated to thebreathable film 74, or to at least a central section 78 of the substrate12 where the nonwoven sheet 72 is laminated to the breathable film 74.

[0104] The substrate 12 is slit or cut along a pair of left transversecutting lines 80 to form a left central section 82 and along a pair ofright transverse cutting lines 84 to form a right central section 86.Suitably, the transverse cutting lines 80 and 84 extend from thetransverse edges 70 to a pair of longitudinal edges 88 of the medialsection 76 of the substrate 12. The substrate 12 is then folded suchthat the left central section 82 and the right central section 86overlay the medial section 76 of the substrate 12 thereby enclosing theabsorbent adhesive composition within the absorbent core 10. Althoughthe medial section 76, the left central section 82 and the right centralsection 86 are illustrated in FIG. 6 as having comparable widthdimensions, it should be understood that the sections may have anydimension suitable to allow the substrate 12 to be folded in a mannerthat encloses the absorbent adhesive composition within the absorbentcore 10.

[0105] As shown in FIG. 6, a pair of fastening means 66 may be providedalong each transverse edge 70 of the substrate 12 adjacent one of thelongitudinal ends 68. The fastening means 66 may be of any type known inthe art such as, for example, tapes, hook and loop fasteners, buttons,snaps and the like. Suitably, the fastening means are refastenable suchthat the diaper 46 may be opened and closed multiple times while in use.Alternatively, the absorbent core 10 may be folded along a transversecenterline 90 such that the longitudinal ends 68 are placed in ajuxtaposed configuration and the transverse edges 70 may be sealed,fused or bonded together to form a 3-dimensional pant. Additionalelements such as, for example, waist elastic positioned adjacent thelongitudinal ends 68 of absorbent core 10, leg elastics incorporatedadjacent longitudinal edges 88 of the medial section 76 of the absorbentcore 10, or extensible side panels incorporated along the transverseedges 70 of the absorbent core 10 adjacent the longitudinal ends 68, maybe incorporated into the absorbent composite to provide better fit,comfort and leakage protection in use.

[0106] Although the diaper 46 illustrated in FIG. 6 has a generally“I”-shaped configuration it is to be understood that otherconfigurations such as an “hour-glass” shape, “trapezoidal” shape or thelike may also be achieved using other folding sequence with or withoutcutting the substrate to form the absorbent core 10. Generally, anyshape that may be achieved by folding and optionally cutting thesubstrate 12 may be used to make an absorbent garment formed from anabsorbent composite of the present invention. The absorbent core 10 maybe further shaped by molding, pressing, trimming, heating or the like toachieve a desired 2- or 3-dimensional configuration. The absorbentcomposite 10 may also be embossed or printed to impart desired surfaceaesthetics.

[0107] It is to be understood that although the foregoing descriptionhas been drafted in terms of a diaper, the present invention may also beused to form similar absorbent articles such as, for example, trainingpants, adult incontinence products and garments, feminine hygienegarments, swimwear, and other absorbent garments.

EXAMPLES Example 1

[0108] An absorbent composite of the present invention was prepared asfollows. A 3-inch×8-inch (about 7.6 centimeter×20.3 centimeter) sheet ofa breathable film having a basis weight of 0.04 osy (about 1.36 gsm) wasplaced in a juxtaposed relationship with a 6-inch×8-inch (about 15.2centimeter×20.3 centimeter) sheet of spunbond material having a basisweight of 0.6 osy (about 20.4 gsm) such that one of the longer edges ofthe film sheet was positioned adjacent one of the longer edges of thespunbond sheet. The film and spunbond were laminated via heat embossingto provide a substrate including a first panel and a second panel. Thefirst panel included the spunbond material and the second panel includedthe spunbond/film laminate.

[0109] The spunbond side of the second panel was hand-coated with anabsorbent crosslinkable binder composition applied uniformly in aconcentration of about 100 grams per square centimeter. Thecrosslinkable binder composition was a copolymer of 57 mole percentacrylic acid, 42 mole percent polyethylene glycol methacrylate, and 1mole percent methacryloxypropyl trimethoxy silane. The acrylic acidportion of the copolymer was neutralized to 50 percent with sodiumhydroxide solution.

[0110] The crosslinkable binder composition was prepared as follows. Aninitiator solution was prepared by dissolving 0.354 grams of benzoylperoxide in 300 milliliters of ethanol. A monomer solution was preparedby mixing 24.15 grams of acrylic acid (24 mass percent), 73.5 grams ofpoly(ethylene glycol) methyl ether methacrylate (74 mass percent) and1.46 grams of 3-(trimethoxysilyl)propyl methacrylate (2 mass percent) in250 milliliters of ethanol. The initiator solution was heated in ajacketed reactor to 75 degrees Celsius with stirring. The monomersolution was added dropwise to the initiator solution to form apolymerization solution. The polymerization solution was stirred andheated at 75 degrees Celsius for approximately 2 hours after which asolution of 0.096 grams azobisisobutyronitrile (AIBN), dissolved in 30milliliters of ethanol, was added. The polymerization solution wasstirred and heated at 75 degrees Celsius for another hour at which timea second solution of 0.096 grams AIBN in ethanol was added to thepolymerization solution. The polymerization solution was stirred andheated at 75 degrees Celsius for an additional hour after which a thirdaddition of 0.096 grams AIBN in ethanol was made. Stirring and heatingof the polymerization solution continued at 75 degrees Celsius for anadditional time to reach a total reaction time of about 7 hours. Thereactor was cooled to 20 degrees Celsius and the resulting polymersolution was stirred in a nitrogen atmosphere overnight to provide abinder polymer designated binder polymer 1 a. A portion of the polymersolution was dried for 16 hours at room temperature to create a sticky,crosslinked water-absorbent film. The polymer concentration of thepolymer solution was 16.2 percent by weight.

[0111] A portion of the polymer solution was treated with sodiumhydroxide solution to neutralize a portion (50 percent) of the acrylicacid units in the binder polymer 1 a in order to increase the absorbencyof the crosslinked film generated by drying the polymer solution. Theneutralization was done by adding 5.25 grams of 48.5 percent sodiumhydroxide solution to 236 grams of polymer solution (16.2 percentpolymer) and stirring at room temperature for 5 minutes.

[0112] The first panel of the substrate was folded over the second panelthereby enclosing the absorbent crosslinkable binder composition betweenthe two panels. The folded substrate was placed on the bottom plate of aflat Carver press, Model 25-15HC (Catalog No. 3977) available from FredS. Carver, Inc., Wabash, Ind. Shims having a thickness of 0.9millimeters were also placed on the bottom plate of the Carver press toprovide gap-stops. Accordingly, when the top and bottom plates of theCarver press were brought together the top plate contacted the shims anda 0.9-millimeter gap was formed between the two plates. The foldedsubstrate was compressed for 10 seconds with a force of 10,000 pounds(44,450 Newtons) at room temperature (approximately 73° F. or 23° C.) toprovide an absorbent composite of the present invention having a“u”-shaped cross-section and a thickness of about 0.9 millimeters.

Example 2

[0113] An absorbent composite of the present invention was prepared asin Example 1 except prior to folding the first panel over the secondpanel a piece of tissue web was placed over the coated portion of thesecond panel. The tissue web was prepared using the Uncreped Through-AirDried (UCTAD) process as described in U.S. Pat. Nos. 5,656,132 and5,932,068 to Farrington, Jr., et al., and had a basis weight of 50 gramsper square meter. The first panel was then folded over the second panelthereby enclosing the absorbent crosslinkable binder composition and theUCTAD sheet between the two panels. After compression, the resultingabsorbent composite had a “u”-shaped cross-section and a thickness ofabout 1.4 millimeters.

Example 3

[0114] An absorbent composite of the present invention was prepared asfollows. A 3-inch×8-inch (about 7.6 centimeter×20.3 centimeter) sheet ofa breathable film having a basis weight of 0.04 osy (about 1.36 gsm) wasplaced in a juxtaposed relationship with a 9-inch×8-inch (about 22.9centimeter×20.3 centimeter) sheet of spunbond material having a basisweight of 0.6 osy (about 20.4 gsm) such that the film sheet waspositioned adjacent a medial 3-inch×8-inch (about 7.6 centimeter×20.3centimeter) section of the spunbond sheet. The film and spunbond werelaminated via heat embossing to provide a substrate including a firstpanel, a second panel, and a third panel having approximately equaldimensions. The first panel included spunbond material, the second panelincluded the spunbond/film laminate and the third panel includedspunbond material.

[0115] The second panel was coated with the absorbent crosslinkablebinder composition as disclosed in Example 1. The first panel wassprayed with a surfactant mixture including AHCOVEL N-62 available fromUniqema Inc., a division of ICI of New Castle, Del., U.S.A. and GLUCOPON220UP available from Cognis Corporation of Ambler, Pa., and produced inCincinnati, Ohio, in an active ratio of 3:1. The surfactant was appliedat a concentration of about 0.45 weight percent based on the totalweight of surfactant and the spunbond material of the first panel.

[0116] The first panel was folded over the second panel therebyenclosing the absorbent crosslinkable binder composition and thesurfactant between the first and second panels. The third panel was thenfolded over the first panel and the folded substrate was placed on thebottom plate of a Carver press. Shims having a thickness of 1.2millimeters were also placed on the bottom plate of the Carver press toprovide gap-stops. The folded substrate was compressed as in Example 1to provide an absorbent composite of the present invention having an“e”-shaped cross-section and a thickness of about 1.2 millimeters.

Example 4

[0117] A feminine hygiene product of the present invention was formedusing the absorbent composite of Example 1 as follows. Three strips of amoisture-insensitive adhesive were applied to the film side of thesecond panel at a concentration of about 5 to about 10 grams per squarecentimeter, and were covered by an adhesive releasable paper. Themoisture-insensitive adhesive was NS-34-5561 available from NationalStarch and Chemical Company of Bridgewater, N.J. The absorbent compositewas die-cut into a dumbbell shape to form a feminine hygiene product.

Example 5

[0118] A piece of surge material made according to U.S. Pat. No.5,364,382 to Latimer et al., manufactured by Kimberly-Clark was coatedwith a mixture of 8.7 grams superabsorbent material and 19.3 grams of acrosslinkable binder composition in 15 percent w/w ethanol. The surgematerial had a basis weight of 1.5 osy (about 50.9 gsm). Thesuperabsorbent material was FAVOR SXM 9543, available from StockhausenInc., located in Greensboro, S.C. The crosslinkable binder compositionwas a copolymer of 70 mole percent acrylic acid, 29 mole percentpolyethylene glycol methacrylate, and 1 mole percent methacryloxypropyltrimethoxy silane. The acrylic acid portion of the copolymer wasneutralized to 70 percent with sodium hydroxide solution.

[0119] The coating was applied with a spatula onto the medial3-inch×12-inch (about 7.6 centimeter×30.5 centimeter) region of a9-inch×12-inch (about 22.9 centimeter×30.5 centimeter) sheet of surgematerial. The coated surge material was placed in a fume hood at roomtemperature to evaporate the ethanol. After the ethanol had evaporated,the surge material was folded as illustrated in FIGS. 6b through 6 d toprovide an absorbent composite of the present invention having an“e”-shaped cross-section that provides both fluid intake and retentionfunctionality.

Example 6

[0120] An absorbent composite of the present invention was prepared asin Example 5 except one of the side sections of the surge material wasfolded over the coated medial section of the surge material prior toevaporating the ethanol. The ethanol was then evaporated in order to setthe binder composition and to adhere the first side section to theabsorbent crosslinkable binder composition to provide more intimatecontact between the coated and uncoated sections. The second sidesection was then folded over the first side section to provide anabsorbent composite of the present invention having an “e”-shapedcross-section.

Example 7

[0121] An absorbent composite including a multifunctional substrate wasprepared as follows. A multifunctional substrate was prepared by placinga first 3-inch×12-inch (about 7.6 centimeter×30.5 centimeter) section ofa 9-inch×12-inch (about 22.9 centimeter×30.5 centimeter) sheet of surgematerial as in Example 5 on the bottom plate of a Carver press. Shimshaving a thickness of 0.5 millimeters were also placed on the bottomplate of the Carver press to provide gap-stops. The top and bottomplates of the Carver press were heated to about 220° F. (about 105° C.).The first section of the surge material was compressed between the topand bottom plates for 60 seconds with a force of 10,000 pounds (44,450Newtons) to increase the density of the first section of the surgematerial. The compressed first section of the surge material had adensity approximately twice that of the uncompressed remainder of thesheet.

[0122] A coating of an absorbent crosslinkable binder composition andsuperabsorbent material as in Example 5 was then applied to a medial3-inch×12-inch (about 7.6 centimeter×30.5 centimeter) section of thesurge material. The surge material was then folded as illustrated inFIGS. 6b through 6 d such that the densified first section of the surgematerial was positioned adjacent the coated medial section of the surgematerial and the undensified, uncoated section of the surge material waspositioned adjacent the densified first section of the surge material toform an absorbent composite having an “e”-shaped cross-section. Theresulting absorbent composite provides intake, distribution, andretention functionality.

Example 8

[0123] An absorbent composite including a multifunctional substrate wasprepared as follows. A multifunctional substrate was prepared as inExample 7. Similar to Example 6, a medial section of the surge materialwas coated with the absorbent cross-linkable binder composition andsuperabsorbent material of Example 5 and the densified section of thesurge material was folded over the coated medial section prior toevaporating the ethanol. After the ethanol was evaporated theundensified section of the surge material was folded over the densifiedsection of the surge material to form an absorbent composite of thepresent invention having an “e”-shaped cross-section.

TEST METHOD FOR DETERMINING ABSORBENT CAPACITY

[0124] Centrifuge Retention Capacity: The Centrifuge Retention Capacity(CRC) is a test which measures the amount-in grams of a test liquid,such as water or a 0.9 weight percent solution of sodium chloride indistilled water, that a gram of a material can absorb or immobilize in asingle time interval, or a series of time intervals, after beingsubjected to a centrifugal force for a period of time.

[0125] Stock teabag material is cut into a 3-inch (about 7.6centimeters) by 5-inch (about 12.7 centimeters) rectangle and folded inhalf to form a 2.5-inch (about 6.4 centimeters) by 3-inch (about 7.6centimeters) rectangle with the sealable face inward. Two of the threeopen sides are heat sealed with the inside edge of the seal about 0.25inch (about 0.64 centimeter) from the edge. About 0.2 gram of samplematerial (or a 1-inch by 1-inch square piece of composite) is placedinto a preweighed teabag, and the open end of the teabag is heat sealed.The teabag is submerged in a pan of test liquid for a time interval,removed, allowed to drain on a wire mesh at about a 45 degree angle forabout 2 minutes, centrifuged for about 3 minutes at 290 times thegravitational force and then weighed. If a series of time intervals isto be run, the sample is returned to the test liquid until the next timeinterval. After each time interval, the teabag is again allowed to drainon the wire mesh for about 2 minutes, again centrifuged for about 3minutes at 290 times the gravitational force, and then weighed again.After the final time interval, the teabag is then allowed to dry andthen weighed again. A blank test is also run by centrifuging, undersimilar conditions, an empty teabag that had also been placed in thetest liquid. The weight of the test liquid retained per gram of drysample material after centrifuging is calculated from the data obtained,and this is expressed as the Centrifuge Retention Capacity value interms of grams of test liquid retained per gram of dry sample material.

TEST METHOD FOR DETERMINING ABSORBENCY UNDER LOAD FOR COMPOSITES (AULC)

[0126] The Absorbency Under Load for Composites (AULC) is a test thatmeasures the ability of an absorbent material to absorb a liquid (suchas a 0.9 weight percent aqueous solution of sodium chloride) while underan applied load or restraining force. The AULC method provides a slightpositive head of fluid for the absorbent material, which is allowed toswell under a restraining load. The material is drained under vacuum atthe end of the test.

[0127] The AULC test cup is cylindrical with a height of at least 1.75inches; the inner diameter describes a cylinder, the base of which hasan area of 4.37 in². The bottom of the test cup is formed by adhering a100 mesh metal screen having 150 micron openings to the end of thecylinder by heating the screen above the melting point of the plasticand pressing the plastic cylinder against the hot screen to melt theplastic and bond the screen to the plastic cylinder. A spacer weighingabout 60 grams and having a circular diameter of about 2.36 inches ismade to fit within the AULC test cup without binding. The spacer isformed with multiple cylinder holes of about 9 mm diameter, providing anopen area of about 52 percent. A 100 mesh screen is adhered to thebottom of the spacer in a similar manner to that of mesh that isattached to the bottom of the test cup or other suitable method. Weightsare sized to fit on top of the spacer. The first weight should apply aload of 600 grams (in combination with the spacer), and the secondweight, in combination with the first weight and the spacer disc, shouldapply a load of 1800 grams.

[0128] Additional equipment required includes a vacuum trap for liquidthat is suctioned out of the composite material at the end of the test,shallow dishes such as Petri dishes or plastic weighing boats suitablefor holding an excess amount of liquid than will be imbibed by thesample, and a thin mesh screen with a thickness between 0.3 mm and 0.75mm and a mesh size of about 1.2 mm. The vacuum trap is adapted to applyvacuum to an area matching the dimensions of the bottom of the AULCtesting cup (for example, a larger vacuum area may be selectivelyscreened with a relatively impermeable material except in an areamatching the dimensions of the bottom of the AULC cup). The vacuumapplied is about 27 inches of mercury.

[0129] Composite samples are cut to fit inside the AULC testing cup.Airlaid or nonwoven-based materials are cut into circles 2.35 inches indiameter. Airformed samples are cut or formed into circles, each with adiameter of 2.312 inches.

[0130] To carry out the test, test cup and spacer should be clean anddry. The test cup and spacer to be used in each trial should be weighedtogether (Measurement 1), and the mass recorded. The specimen is placedin the sample cup and the spacer is placed on top of the sample in thecup. The assembly is then weighed (Measurement 2), and the mass isrecorded. The appropriate amount of weight is placed atop the spacer, ifrequired. The spacer alone applies a force of 0.03 pounds per squareinch of area (psia; the disc and first weight, with a net mass of 600grams, apply a force of 0.3 psi, and the disc and both weights together,having a net mass of 1800 grams, apply a force of 0.9 psi).

[0131] The cup holding the specimen is placed in a pool of excess fluidin the shallow dish on top of the mesh screen and a one hour timer isstarted immediately. The level of fluid in the dish is maintainedbetween about 1 mm and 2 mm depth. Following one hour, the specimen isremoved from the fluid bath. Any fluid that may have accumulated atopthe specimen should be poured off without displacing any weights atopthe spacer disc. The specimen assembly is then placed on the vacuum box,with any weights still in place. Vacuum is applied to the sample for 30seconds.

[0132] Any weights atop the spacer are then removed from the assemblyand the assembly is weighed again (Measurement 3). The mass is recorded.

[0133] The dry weight of the specimen is calculated by subtractingMeasurement 1 from Measurement 2. The amount of fluid absorbed by thespecimen is calculated by subtracting Measurement 2 from Measurement 3.The absorbency under load of the composite material is calculated as theamount of fluid absorbed divided by the dry weight of the specimen.

[0134] At least three specimens of each sample should be measured, andthe absorbency under load values should be averaged to obtain an overallabsorbency under load for the composite sample.

TEST FOR DETERMINING TENSILE STRENGTH

[0135] The tensile strength can be measured using the Strip Tensile TestMethod described in U.S. Statutory Invention Registration No. H1,969issued to Fell on 5 Jun. 2001.

TEST FOR DETERMINING THICKNESS

[0136] All measurements of composite thickness were done at a pressureof 0.05 psi (0.34 kPascals) with a Mitutoyo Digimatic Indicator (TypeIDF 150E), available from Mitutoyo American Corporation of Aurora, Ill.,equipped with a “foot” composed of a plastic disk having a diameter of 3inches (7.6 centimeters) and a weight of 78.5 grams. The instrument iszeroed with the foot in contact with the baseplate. A sample is placedon the baseplate and the foot is lowered onto the sample until a load of0.05 psi (0.34 kPascals) is applied. The thickness of the sample is thenmeasured to the nearest 0.01 millimeter.

TEST METHOD FOR DETERMINING STIFFNESS

[0137] A suitable technique for determining the stiffness valuesdescribed herein is a Gurley Stiffness test, a description of which isset forth in TAPPI Standard Test T 543 om-94 (Bending Resistance ofPaper (Gurley type tester)). A suitable testing apparatus is a GurleyDigital Stiffness Tester, Model 4171-E, manufactured by Teledyne Gurley,a business having offices in Troy, N.Y. For purposes of the presentinvention, the stated Gurley stiffness values are intended to correspondto the values that would be generated by a “standard” sized sample.Accordingly, the scale readings from the Gurley stiffness tester areappropriately converted to the stiffness of a standard size sample, andare traditionally reported in terms of milligrams of force (mgf).Currently, a standard “Gurley unit” is equal to a stiffness value of 1mgf, and may equivalently be employed to report the Gurley stiffness.

[0138] While in the foregoing specification this invention has beendescribed in relation to certain preferred embodiments thereof, and manydetails have been set forth for purpose of illustration, it will beapparent to those skilled in the art that the invention is susceptibleto additional embodiments and that certain of the details describedherein can be varied considerably without departing from the basicprinciples of the invention.

What is claimed is:
 1. An absorbent core comprising a substrate thatperforms a first fluid handling function wherein the substrate is foldedto provide a plurality of panels, and at least a portion of at least onepanel corresponds to at least a portion of one region of the substratethat has been modified to perform a different fluid handling function.2. The absorbent core of claim 1, wherein the substrate comprises amaterial selected from the group consisting of nonwoven webs, wovenwebs, knitted fabrics, cellulosic tissue sheets, plastic films, foams,stranded composites, elastomer net composites and combinations thereof.3. The absorbent core of claim 1, wherein the substrate is folded toprovide an absorbent core having a cross-sectional configurationselected from the group consisting of an “e”-shape, a “z”-shape, a“c”-shape, a sigma-shape, a “u”-shape and an accordion-shape.
 4. Theabsorbent core of claim 1, wherein the fluid handling functions areselected from the group consisting of body waste barrier, distribution,feces containment, feces modification, intake, lock-up, mensescontainment, menses modification, odor control, retention, and skintreatment.
 5. The absorbent core of claim 1, wherein at least one regionof the substrate has been modified by aperturing, calendaring, coating,creping, heating, printing, stretching or a combination thereof.
 6. Theabsorbent core of claim 1, wherein at least a portion of one panelcorresponds to at least a portion of a region of the substrate that hasbeen apertured.
 7. The absorbent core of claim 1, wherein at least aportion of one panel corresponds to at least a portion of a region ofthe substrate that has been calendered.
 8. The absorbent core of claim7, wherein the panel corresponding to at least a portion of thecalendered region of the substrate has a first density and at least aportion of a second panel has a different density.
 9. The absorbent coreof claim 1, wherein at least a portion of one panel corresponds to aregion of the substrate that has been coated with a modifying material.10. The absorbent core of claim 9, wherein the modifying material isselected from the group consisting of a fluid modifying material, abinding agent, an absorbent material, an odor control agent, andcombinations thereof.
 11. The absorbent core of claim 9, wherein thesubstrate is folded such that at least a portion of the modifyingmaterial is enclosed within the absorbent core.
 12. The absorbent coreof claim 10, wherein the fluid modifying material comprises aviscoelastant, a surfactant or a combination thereof.
 13. The absorbentcore of claim 10, wherein the binding agent is selected from the groupconsisting of absorbent adhesive compositions, non-absorbent adhesivecompositions, and combinations thereof.
 14. The absorbent core of claim13, wherein the absorbent adhesive compositions include an in situneutralizable binder composition, an in situ polymerizable bindercomposition, a crosslinkable binder composition, or combinationsthereof.
 15. The absorbent core of claim 14, wherein the in situneutralizable binder composition includes a copolymer of anunneutralized polyacid and a polyamine binder material.
 16. Theabsorbent core of claim 15, wherein the copolymer of an unneutralizedpolyacid comprises a material selected from the group consisting ofpoly(acrylic acid), poly(methacrylic acid), poly(maleic acid),carboxymethyl cellulose, alginic acid, poly(aspartic acid), andpoly(glutamic acid).
 17. The absorbent core of claim 15, wherein thepolyamine binder material comprises a material selected from the groupconsisting of poly(vinylamine), a polyethylenimine, apoly(vinylguanidine), a poly(allylamine), a poly(allylguanidine), apoly(lysine), a poly(arginine), a poly(histidine), apoly(dialkylaminoalkyl (meth)acrylamide), and copolymers containinglysine, arginine or histidine.
 18. The absorbent core of claim 15,wherein the substrate is folded such that the copolymer of anunneutralized polyacid and the polyamine binder material are broughttogether in such a manner to provide a macro bipolar absorbent film. 19.The absorbent core of claim 14, wherein the crosslinkable bindercomposition comprises a soluble polymer selected from the groupconsisting of hydrophilic polymers, a blend of hydrophilic polymerscontaining hydrophilic agents, and a blend of hydrophobic polymersincluding hydrophilic agents.
 20. The absorbent core of claim 14,wherein the crosslinkable binder composition comprises an alkoxysilanegrafted poly(ethylene oxide).
 21. The absorbent core of claim 14,wherein the crosslinkable binder composition has a glass transitiontemperature of 30 degrees Celsius or lower.
 22. The absorbent core ofclaim 14, wherein the crosslinkable binder composition comprises anacrylic acid copolymer selected from the group consisting of acrylicacid and long chain, hydrophilic acrylate esters, acrylic acid and longchain, hydrophilic methacrylate esters, and acrylic acid salts and longchain, hydrophilic methacrylate esters.
 23. The absorbent core of claim10, wherein the absorbent material has an absorbent capacity of at leastabout 7 grams 0.9 weight percent saline per gram absorbent material. 24.The absorbent core of claim 23, wherein the absorbent material comprisesa superabsorbent material selected from the group consisting ofcrosslinked forms of sodium polyacrylate, sodium polymethacrylate,polyacrylamide, carboxymethyl cellulose, grafted starch, poly(sodiumaspartate), poly(vinyl amine), poly(dimethyldiallyl amine), chitosansalt, and/or poly(ethylene imine) and combinations thereof.
 25. Theabsorbent core of claim 23, further comprising an attachment mechanismfor securing the absorbent material to the substrate, the attachmentmechanism selected from the group consisting of physical bonds, chemicalbonds and combinations thereof.
 26. An absorbent article comprising theabsorbent core of claim
 1. 27. The absorbent article of claim 26,wherein the absorbent article is selected from the group consisting ofmedical products, wipes, tissues, underarm sweat pads, bed mats,urinals, and the like.
 28. An absorbent garment comprising an absorbentcore wherein the absorbent core includes a substrate that performs atleast one fluid handling function that has been folded to provide aplurality of panels, and at least a portion of at least one panelcorresponds to at least a portion of a region of the substrate that hasbeen modified to impart a different fluid handling function.
 29. Theabsorbent garment of claim 28, wherein the absorbent garment comprises agarment selected from the group consisting of diapers, training pants,adult incontinence products, sanitary napkins, and the like.
 30. Theabsorbent garment of claim 28, further comprising: a body-side liner;and a garment-side cover, wherein the absorbent core is disposed betweenthe body-side liner and the garment-side cover.
 31. The absorbentgarment of claim 28, wherein the garment has an average thickness ofabout 6.4 millimeters or less.
 32. A process for making an absorbentcore comprising: providing a substrate that performs at least one fluidhandling function; modifying at least a portion of one region of thesubstrate to impart at least one different fluid handling function; andfolding the substrate to provide a plurality of panels, wherein at leasta portion of at least one panel corresponds to at least a portion of themodified region of the substrate.
 33. The process of claim 32, whereinat least a portion of at least one region of the substrate is modifiedby aperturing, calendaring, coating, creping, heating, printing,stretching, or a combination thereof.
 34. The process of claim 32,wherein the substrate is folded to provide an absorbent core having across-sectional configuration selected from the group consisting of an“e”-shape, a “z”-shape, a “c”-shape, a sigma-shape, a “u”-shape and anaccordion-shape.
 35. The process of claim 32, further comprising shapingthe absorbent core.